整体叶盘叶片加工补偿策略及实验研究

Compensation Strategy and Experimental Study on Integral Disk and Blade Processing

目的降低航天发动机整体叶盘的加工误差,实现产品高精度化。方法建立整体叶盘叶片加工变形量全局分布有限元模型,考虑补偿加工时刀具修正量与变形误差的耦合效应,采用多次迭代法计算叶片变形补偿量;提出反向重构几何模型补偿策略,利用补偿量对叶片几何轮廓进行重构,重新生成包含叶片变形误差信息的刀轨程序。通过某型号航空发动机整体叶盘叶片铣削加工实验和型面精度测量实验,对变形分布预测模型及所提出的反向重构模型补偿策略进行验证。结果预测结果与实验结果有很好的吻合度,平均误差为7.96%;新的补偿策略数据嵌入方式高效,可显著降低加工过程中产生的变形误差,将成品精度控制在设计的许用公差范围以内。结论所提方法可以明显提高整体叶盘叶片铣削加工质量,可为后续磨削加工提供更高型面精度的叶片零件。

The work aims to reduce the processing errors of the integral blade disk of the aerospace engine and achieve high precision of the product.A finite element model for the global distribution of processing deformation of the integral disk and blade was established.Considering the coupling effect of tool correction and deformation error during compensation processing,the blade deformation compensation was calculated by a multiple iteration method.A reverse reconstruction geometric model compensation strategy was proposed,which used the compensation amount to reconstruct the blade geometric contour and regenerate the tool path program containing blade deformation error information.The deformation distribution prediction model and the proposed reverse reconstruction model compensation strategy were validated through milling experiments and surface accuracy measurement experiments on the integral blade of a certain aerospace engine.The results showed a good agreement between the predicted results and the experimental results,with an average error of 7.96%.The new compensation strategy data embedding method was efficient and could significantly reduce deformation errors generated during the processing,controlling the precision of the finished product within the allowable tolerance range of the design.The method proposed can significantly improve the milling quality of integral disk and blade,providing higher surface accuracy for subsequent grinding of blade parts.